Organometallic compound in solid form, process for preparing the same and use thereof

ABSTRACT

The present invention provides a solid organomagnesium precursor having formula {Mg(OR′)X}.a{MgX 2 }.b{Mg(OR′) 2 }.c{R′OH}, wherein R′ is selected from a hydrocarbon group, X is selected from a halide group, and a:b:c is in range of 0.01-0.5:0.01-0.5:0.01-5 and process for preparing the same, said process comprising contacting a magnesium source with a solvating agent, an organohalide and an alcohol to obtain the solid organomagnesium precursor. The present invention also provides a process for preparing a catalyst system using the organomagnesium precursor and its use thereof for polymerization of olefins.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.15/371,193, filed Dec. 6, 2016, which is a divisional of U.S. patentapplication Ser. No. 14/416,609, which is the U.S. national stage ofinternational patent application no. PCT/M2013/058797, filed Sep. 24,2013, which claims priority to Indian patent application no.2765/MUM/2012 filed on Sep. 24, 2012. The foregoing patent applicationsare incorporated herein by reference.

FIELD OF INVENTION

The present invention relates to a catalyst system. More particularly,the present invention relates to a solid organomagnesium precursor forthe catalyst system and process for preparing the same. The presentinvention also provides a process for preparing a catalyst system usingthe solid organomagnesium precursor and its use thereof forpolymerization of olefins.

BACKGROUND OF INVENTION Ziegler-Natta catalyst systems are well knownfor their capability to polymerize olefins. They in general consist of asupport which mostly is magnesium based onto which titanium componenthas been added along with organic compound known as internal donor. Thiscatalyst when combined with co-catalyst and/or external donor compriseof the complete ZN catalyst system.

Ziegler-Natta catalyst system typically consists of transition metalhalide normally titanium halide supported on metal compound which istypically magnesium dichloride. Along with transition metal, there is anorganic component known as internal electron donor that plays a typicalrole during catalyst synthesis and polymerization. MgCl₂ carrier, wherethe MgCl₂ is in active form, can be created by various methodologies.One of the methods is precipitating the MgCl₂ from an organic solutionwhere magnesium is present as a soluble compound. The soluble magnesiumcompound can be achieved by starting from a magnesium alkyl and treatingit with an alcohol. This step is then followed by chlorination of Mgalkyl or alkoxy compounds by a chlorination agent. The magnesium carriercan also be precipitated in the form of ‘ready-made’ MgCl₂. In that casethe MgCl₂ has to be dissolved first in some suitable donor compound andthen precipitated in hydrocarbon solvent. The MgCl₂ support material canalso be precipitated by chlorinating a soluble magnesium alkyl compoundsimply by treating it with chlorine gas or hydrochloric acid. Once thedesired specification of carrier is obtained, this is generally followedby titanation procedure which finally results in the catalyst synthesis.

U.S. Pat. No. 4,220,554 of Montedison describes the process ofsynthesizing the catalyst by treating Ti compounds with a sphericalcarrier which consists of Mg compound having the formulaX_(n)Mg(OR)_(2-n). X_(n)Mg(OR)_(2-n) is synthesized by in reacting, in asingle step, Mg metal, the organic halide and the orthosilicic acidester. This product is isolated and then treated with halide of aromaticacid which is again isolated and treated with Ti compound for formationof catalyst. This catalyst is evaluated for propylene polymerization.This route applies the usage of orthosilicic ester for generation ofmagnesium alkoxy halide compound and focuses on the particle shape aswell as size of the catalyst.

U.S. Pat. No. 4,727,051 of Stauffer Chemical Company discloses theprocess for synthesis of X_(n)Mg(OR)_(2-n) by preparing an alkanoladduct of a magnesium halide, reacting the product of this step withmetallic magnesium, and drying the product. The compositions are thenevaluated for as catalysts of olefin polymerization. The maindisadvantage of this process is the usage of magnesium halides and largeamount of alcohols.

U.S. Pat. No. 4,820,672 of Lithium Corporation of America describes theprocess for producing magnesium halide alcohol complex by reacting in anether free hydrocarbon reaction medium, magnesium metal, dialkylmagnesium, alkyl magnesium halide, alkyl magnesium alkoxide, magnesiumdialkoxide and alkoxy magnesium halide with an anhydrous hydrogen halidein the presence of chlorosubstituted alcohol. Further this complex isused for synthesis of ZN catalyst. The main disadvantage of this processis a large number of steps are involved for magnesium halide alcoholsynthesis and further the usage of hydrogen halide which is difficult tohandle. US4820879 further describes the process where alkoxy magnesiumhalides are formed by reacting preactivated magnesium with alcohol athigher temperatures and then treating it with hydrogen halides. Herealso usage and handling of hydrogen halide is quite troublesome.

U.S. Pat. No. 4,792,640 discloses a process for synthesis of solidhydrocarbyloxymagnesium halides which is ether free, where preactivated(with iodine) magnesium metal is reacted with alkyl halide for some timeand then addition of alcohol is done dropwise and finally refluxed. Thesolid product is filtered, dried and analyzed. Here the Grignard isstabilized in hydrocarbon. These patents contains no information on theactivity of the ZN catalyst synthesized thereof.

U.S. Pat. No. 5,081,320 of Akzo NV describes the synthesis ofalkoxymagnesium halides from secondary alcohol containing alkylbranching on the alpha carbon atom which is soluble in inerthydrocarbon. The process involves heating inert hydrocarbon solvent,secondary alcohol and ethanol with magnesium halide (MgCl₂) to dissolvethe magnesium halide. Magnesium metal is then added along withadditional solvent to prepare a soluble alkoxymagnesium halide. Onedisadvantage of this process is one need to prepare soluble magnesiumalkoxide in order to further react the magnesium metal. U.S. Pat. No.5,108,972 discloses the process of synthesis of alkoxymagnesium halideusing non Grignard route where they react magnesium halide and magnesiumalkoxide in excess of alcohol. Further magnesium source can also beadded which is generated through dialkylmagnesium in hydrocarbon. Maindisadvantage of this process is usage of expensive raw materials andlarge number of steps. The patent describes the process of synthesizingthe magnesium compounds only.

U.S. Pat. No. 5,414,158 of Witco GmbH describes the one step synthesisof alkoxymagnesium halides in an inert hydrocarbon by reactingpreactivated magnesium with small quantities of magnesium alkyl, withalmost equimolar mixture of an alkyl halide and an alkanol. The obtainedproduct is in excess of 90%. In this process first magnesium needs to beactivated with magnesium alkyl at high temperature and then addition iscarried out dropwise to the alkylhalide and alkanol mixture. Onedisadvantage of this process is requirement of expensive magnesium alkylfor activation which is also difficult to handle and further the extraaddition of alkanol after the reaction to reduce viscosity. This patentdescribes the synthesis of alkoxymagnesium halide only and doesn't statethe usage of the same as precursor for ZN catalyst.

EP1273595 of Borealis describes the process for synthesis of catalyst byreacting dialkylmagnesium with monohydric alcohol followed bydicarboxylic acid dihalide and chlorinated hydrocarbons. After washingand isolation of this product, it is further treated with titaniumcompound for the formation of ZN catalyst which shows activity forpropylene polymerization. The main disadvantage of this process is usageof expensive dialkylmagnesium and its handling. This patent is mainly onthe usage of emulsion stabilizer for controlling the particle size andshape.

U.S. Pat. No. 7,135,531 of BASF discloses the process for the synthesisof spherical catalyst which essentially contains titanium, internaldonor and a support made from a magnesium compound, an alcohol, ether, asurfactant, and an alkyl silicate. The magnesium compound mainlymagnesium dichloride is dissolve in alcohol at higher temperature andthen treated with ether at lower temperature followed by addition ofemulsifier at still lower temperature. This is then treated withsilicate and titanium compound and final catalyst is ready after washingand drying. The main disadvantage of this process is higher alcoholcontent and expensive raw materials.

US2009/0306315 of SABIC discloses the process for preparing apolymerization catalyst which is synthesized by reacting Mg(OR¹)_(x)Cl_(2-x), which is obtained by reacting a Grignard compoundwith an alkoxy or aryloxy silane compound, with electron donor in thepresence of inert dispersant to give an intermediate reaction productwhich is then treated with titanium halide to give the final catalystwhich shows activity for olefin polymerization. This process has maindisadvantage that its involves large number of steps which mainlyconsists of first solubilizing the magnesium compound and thensolidifying before making final catalyst.

Thus, it would be desirable to provide a solid organometallic precursorcompound for synthesis of a catalyst for polymerization of olefins thatcould be synthesized through a single step process using less expensiveraw materials and lower alcohol content. Further, it would be desirableif the organometallic compound could be isolated, without any furtherpurification and used as a precursor for making olefin polymerizationcatalyst which is highly active with low xylene solubility and excellenthydrogen response.

SUMMARY OF INVENTION

Accordingly the present invention provides a process for preparation ofa solid organomagnesium precursor having formula {Mg(OR′)X}.a{MgX₂}.b{Mg(OR′)₂}.c{R′OH}, wherein R′ is selected from a hydrocarbon group, Xis selected from a halide group, and a:b:c is in range of0.01-0.5:0.01:0.5:0.01-5, said process comprising contacting a magnesiumsource with a solvating agent, an organohalide and an alcohol to obtainthe solid organomagnesium precursor.

The present invention also provides a process for preparation of acatalyst composition, said process comprises:

(a) contacting a solution of transition metal compound represented byM(OR′″)_(p)X_(4-p), where M is a transition metal and selected from Ti,V, Zr, and Hf; X is a halogen atom; R′″ is a hydrocarbon group and p isan integer having value equal or less than 4 and where M is preferablytitanium with the solid organomagnesium precursor having formula{Mg(OR′)X}.a{MgX₂}.b{Mg(OR′)₂}.c{R′ OH}, wherein R′ is selected from ahydrocarbon group, X is selected from a halide group, and a:b:c is inrange of 0.01-0.5:0.01:0.5:0.01-5, to obtain the resulting solution andcontact temperature of the solid organomagnesium precursor and thetransition metal compound is between about −50° C. and about 150° C.,and preferably between about −30° C. and about 120° C.;

(b) adding an internal donor either to the organomagnesium precursorcomponent or to the titanium component and the contact time of the saidcomponent with the internal electron donor is either immediate or atleast 1 minutes to 60 minutes at contact temperature of between about−50° C. and about 100° C., and preferably between about −30° C. andabout 90° C.; (c) treating the resulting solution obtained in the step(a) with a solution comprising a neat titanium component or a titaniumcomponent in a solvent and recovering a solid titanium catalystcomponent and maintaining the same at a temperature value in the rangeof 100 to 120° C. for about 10 to 60 minutes; and

(d) optionally repeating step (c) for a predetermined number of timesand then washed sufficiently with inert solvent at temperature 20° C. to90° C. to obtain a solid catalysts composition.

The present invention also provides a process for preparation of aZiegler-Natta catalyst system, said process comprising contacting thecatalyst composition as obtained above with at least one cocatalyst, andat least one external electron donor to obtain a Ziegler-Natta catalystsystem.

The present invention also provides a method of polymerizing and/orcopolymerizing olefins, said method comprising the step of contacting anolefin having C2 to C20 carbon atoms under a polymerizing condition withthe Ziegler-Natta catalyst system as obtained above.

BRIEF DESCRIPTION OF DRAWING

FIG. 1 illustrates NMR spectra for the compound{Mg(OR′)X}.a{MgX₂}.b{Mg(OR′)₂}.c{R′OH}.

DETAILED DESCRIPTION OF INVENTION

While the invention is susceptible to various modifications andalternative forms, specific embodiment thereof will be described indetail below. It should be understood, however that it is not intendedto limit the invention to the particular forms disclosed, but on thecontrary, the invention is to cover all modifications, equivalents, andalternative falling within the scope of the invention as defined by theappended claims.

The present invention discloses solid organometallic compound and aprocess of preparation of the solid organomagnesium compound. Furtheraccording to the present invention the organomagnesium compound acts asa precursor for Ziegler-Natta catalyst system and there is provided aprocess for synthesis of the catalyst system using the precursorthereof. Catalyst compositions and systems synthesized fromorganomagnesium compounds are able to polymerize olefins. The solidorganomagnesium compound according to the present invention providesprecursor based catalyst system has high activity, excellent hydrogenresponse, high selectivity and better co-monomer distribution.

According to the present invention, the solid organomagnesium compoundis prepared by a single step process first by generating Grignardreagent followed by reacting with an alcohol. The isolated solidorganomagnesium compound when contacted with metal compound M where Mcan be selected from Ti,V, Zr, Hf and along with the internal electrondonors provide the catalyst system. The solid organomagnesium compoundsynthesis according to the present invention is achieved with reducedalcohol content without any further purification step. This catalystsystem comprising of the said component have high activity for olefinpolymerization with excellent hydrogen response and highstereospecificity.

Further, the present invention relates to the synthesis of Ziegler-Nattacatalysts by using solid organomagnesium compound as a precursor. TheZiegler-Natta catalyst according to the present invention is preparedthrough precipitation, physical blending of solid mixtures, and in situformation of halogenating agents. The resulting catalyst exhibits highactivity for olefin polymerization with excellent hydrogen response.

Further, the invention provides a process of polymerizing and/orcopolymerizing the olefin using the catalyst produced through theprocess mentioned in the invention.

Accordingly the present invention provides a process for preparation ofa solid organomagnesium precursor having formula{Mg(OR′)X}.a{MgX₂}.b{Mg(OR′)₂}.c {R′OH}, wherein R′ is selected from ahydrocarbon group, X is selected from a halide group, and a:b:c is inrange of 0.01-0.5:0.01:0.5:0.01-5, said process comprising contacting amagnesium source with a solvating agent, an organohalide and an alcoholto obtain the solid organomagnesium precursor.

In one of the preferred embodiment, a solid organomagnesium precursorhaving formula {Mg(OR′)X}.a{MgX₂}.b{Mg(OR′)₂}.c{R′OH}, can be preparedas shown in below scheme 1:

According to the present invention, the process involves contactingmagnesium source with organohalide compound and solvating agent forparticular time and at particular temperature followed by reacting withalcohol. The magnesium source used in the present invention includes,not limited to, for example magnesium metal in form of powder, granules,ribbon, turnings, wire, blocks, lumps, chips; dialkylmagnesium compoundssuch as dimethylmagnesium, diethylmagnesium, diisopropylmagnesium,dibutylmagnesium, dihexylmagnesium, dioctylmagnesium,ethylbutylmagnesium, and butyloctylmagnesium; alkyl/aryl magnesiumhalides such as methylmagnesium chloride, ethylmagnesium chloride,isopropylmagnesium chloride, isobutylmagnesium chloride,tert-butylmagnesium chloride, benzylmagnesium chloride, methylmagnesiumbromide, ethylmagnesium bromide, isopropylmagnesium bromide,isobutylmagnesium bromide, tert-butylmagnesium bromide, hexylmagnesiumbromide, benzylmagnesium bromide, methylmagnesium iodide, ethylmagnesiumiodide, isopropylmagnesium iodide, isobutylmagnesium iodide,tert-butylmagnesium iodide, and benzylmagnesium iodide. These magnesiumcompounds may be in the liquid or solid state. The magnesium compound ispreferably magnesium metal.

In an embodiment of the present invention, the organohalide which iscontacted with magnesium compound, includes, not limited to, for examplealkyl halides such as methyl chloride, ethyl chloride, propyl chloride,isopropyl chloride, 1,1-dichloropropane, 1,2-dichloropropane, 1,3 -dichl oroprop ane, 2,3 -di chl oroprop ane, butyl chloride,1,4-dichlorobutane, tert-butylchloride, amylchloride, tert-amylchloride,2-chloropentane, 3-chloropentane, 1,5-dichloropentane,1-chloro-8-iodoctane, 1-chloro-6-cyanohexane, cyclopentylchloride,cyclohexylchloride, chlorinated dodecane, chlorinated tetradecane,chlorinated eicosane, chlorinated pentacosane, chlorinated triacontane,iso-octylchloride, 5-chloro-5-methyldecane, 9-chloro-9-ethyl-6-methyleiscosane; halognetaed alkyl benzene/benzylic halides, such as benzylchloride and α,α′ dichloro xylene; wherein the alkyl radical containsfrom about 10 to 15 carbon atoms, and the like as well as thecorresponding bromine, fluorine and iodine substituted hydrocarbons.These organohalides may be used alone or in the form of mixture thereof.The organohalide is preferably benzyl chloride or butyl chloride ortheir mixtures thereof.

In an embodiment of the present invention, the solvating agent whichstabilizes the Grignard, includes, not limited to, for example dimethylether, diethyl ether, dipropyl ether, diisopropyl ether, ethylmethylether, n-butylmethyl ether, n-butylethyl ether, di-n-butyl ether,di-isobutyl ether, isobutylmethyl ether, and isobutylethyl ether and thelike. Also polar solvents, including but not limited to, dioxane,tetrahydrofuran, 2-methyl tetrahydrofuran, tetrahydropyran,chlorobenzene, dichloromethane and the like. Also non-polar solventslike toluene, heptane, hexane, and the like. These solvating agents maybe used alone or in the form of mixture thereof. The preferred solvatingagent is diethyl ether or tetrahydrofuran or their mixture.

In an embodiment of the present invention, the components may be addedin any order, highly preferably, magnesium followed by solvating agent,organohalide, and alcohol.

In an embodiment of the present invention, the reaction process can bedone as single step such as reacting the components in one pot ormultiple steps such as reacting magnesium, organic halide and solvatingagent first and then addition of alcohol or reacting magnesium withsolvating agent followed by addition of organic halide and alcohol,separately or as a mixture.

The quantity of organohalide depends upon the quantity of magnesiumsource used. According to the preferred embodiment, the magnesium sourceis reacted with the said organohalide in a molar ratio of between 1:20to 1:0.2, preferably between about 1:10 to 1:0.5, more preferably,between 1:4 to 1:0.5. In another embodiment, the magnesium source andsolvating agent are taken as molar ratio of between 1:20 to 1:0.2,preferably between about 1:15 to 1:1, more preferably, between 1:10 to1:1. Another embodiment of the present invention, formation ofhomogeneous solution of magnesium component in solvating agent such asether is desirable. For attaining this, the magnesium source,organohalide, solvating agent are contacted at temperature preferablybetween about −20° C. and about 200° C., and preferably between about−10° C. and about 140° C., more preferably between −10° C. to 100° C.Usually, the contact time is for about 0.5 to 12 h.

In an embodiment of the present invention, reaction promoters likeiodine, the organohalides, inorganic halides such as CuCl, MnCl₂, AgCl,nitrogen halides like N-halide succinimides, trihaloisocynauric acidacompounds, N-halophthalimide and hydrantoin compounds.

In an embodiment, the alcohol contacted includes, no limited to, forexample, aliphatic alcohols such as methanol, ethanol, propanol,butanol, iso-butanol, t-butanol, n-pentanol, iso-pentanol, hexanol,2-methylpentanol, 2-ethylbutanol, n-heptanol, n-octanol, 2-ethylhexanol,decanol and dodecanol, alicyclic alcohols such as cyclohexanol andmethylcyclohexanol, aromatic alcohols such as benzyl alcohol andmethylbenzyl alcohol, aliphatic alcohols containing an alkoxy group,such as ethyl glycol, butyl glycol; diols such as catechol, ethyleneglycol, 1,3-propanediol, 1,4-butanediol, 1,5 -pentanediol,1,8-octanediol, 1,2-propanediol, 1,2-butanediol, 2,3 -butanediol1,3-butanediol, 1,2-pentanediol, p-menthane-3,8-diol,2-methyl-2,4-pentanediol. The alcohols may be used alone or in the formof mixture thereof. The preferred alcohol is 2-ethyl-1-hexanol and itsmixture thereof.

The quantity of alcohol depends upon the quantity of magnesium compoundused. According to the preferred embodiment, the magnesium source alongwith organohalide is reacted with the said alcohol in a molar ratio ofbetween 1:20 to 1:0.2, preferably between about 1:10 to 1:0.5, morepreferably, between 1:4 to 1:0.5. In another embodiment of the presentinvention, formation of homogeneous solution of magnesium component inalcohol is desirable. For attaining this, the solution obtained byreacting magnesium compound, organohalide, in solvating agent iscontacted with alcohol compound at temperature preferably between about0° C. and about 150° C., and more preferably between about 10° C. andabout 120° C. The preferred contact time according to the invention, isfor about 0.5 to 12 h.

The present invention provides the process of preparation of stablesolid organomagnesium compound. In an embodiment, the process involvescontacting magnesium compound with organohalide compound and solvatingagent for particular time and at particular temperature followed byreacting with alcohol. In an embodiment, the addition of organohalide,solvating agent and alcohol can be one shot, dropwise and/or controlled.In an embodiment, the resulting stable solid organomagnesium precursorsolution can be isolated from solvating agent either using reducedpressure with and/or without heating, through precipitation,recrystallization. In another embodiment, the precipitated solid can beeither used directly or in solution form for catalyst synthesis where inthe solvent used for dissolving solid can be from the following groupbut not limited to polar and non polar aliphatic and/or aromatichydrocarbons and combination thereof.

The present invention provides the process of preparation of stablesolid organomagnesium compound. In an embodiment, the process involvescontacting magnesium compound with organohalide compound and solvatingagent for particular time and at particular temperature followed byreacting with alcohol. In an embodiment, the resulting organomagnesiumcompound can be dissolved in polar organic solvents and precipitated inorganic solvents for examples not limiting to linear, branched,aromatic, cyclic, ring substituted, halide substituted alkanes and thelikes, preferably non polar organic solvents or vice versa. In anotherembodiment, the precipitation methodology can be adopted during anystage of precursor synthesis for example but not limiting to, reactingmagnesium with organic halide in solvating agent followed byprecipitation in the mixture of alcohol and precipitating solvent orvice versa, or reacting magnesium with organic halide in solvating agentfollowed by addition of alcohol and then precipitating in precipitatingsolvent or vice versa.

Further, the present invention provides a catalyst composition. Thecatalyst composition includes combination of a magnesium moiety, othermetal moiety and an internal donor. The magnesium moiety includes thestable solid organomagnesium compound of the present invention. Theother metal moiety can be a main group metal or a transition metal, or atransition metal of IIIB-VIIIB element. In an embodiment, the transitionmetal is selected from, Ti, V, Zr and Hf, preferably, Ti.

In one of the embodiment, the present invention provides a process forpreparation of a catalyst composition, said process comprises:

(a) contacting a solution of transition metal compound represented byM(OR′)_(p)X_(4-p), where M is a transition metal and is selected from agroup comprising of Ti, V, Zr, and Hf, preferably Ti; X is a halogenatom; R′″ is a hydrocarbon group and p is an integer having value equalor less than 4, with the solid organomagnesium precursor component ofpresent invention to obtain a resulting solution and contact temperatureof solid organomagnesium precursor and the transition metal compound isbetween about −50° C. and about 150° C., and preferably between about−30° C. and about 120° C.;

(b) adding an internal donor either to the solid organomagnesiumprecursor component or to the titanium component, preferably toorganomagnesium compound; and the contact time of the said componentwith the internal electron donor immediate or is at least 1 minutes to60 minutes at contact temperature of between about −50° C. and about100° C., and preferably between about −30° C. and about 90° C.;

(c) treating the resulting solution obtained in the step (a) with asolution comprising a titanium component in a solvent and recovering asolid titanium catalyst component and maintaining the same at atemperature value in the range of 100 to 120° C. for about 10 to 60minutes; and

(d) optionally repeating step (c) for a predetermined number of timesand then washed sufficiently with inert solvent at temperature 20° C. to80° C. to obtain a solid catalysts composition.

In yet another embodiment of the present invention, the transition metalcompound represented by M(OR′″)_(p)X_(4-p) is selected from a groupcomprising of transition metal tetrahalide, alkoxy transition metaltrihalide/aryloxy transition metal trihalide, dialkoxy transition metaldihalide, trialkoxy transition metal monohalide, tetraalkoxy transitionmetal, and mixtures thereof; wherein:

(a) the transition metal tetrahalide is selected from a group comprisingof titanium tetrachloride, titanium tetrabromide and titaniumtetraiodide and the likes for V, Zr and Hf;

(b) alkoxy transition metal trihalide/aryloxy transition metal trihalideis selected from a group comprising of methoxytitanium trichloride,ethoxytitanium trichloride, butoxytitanium trichloride andphenoxytitanium trichloride and the likes for V, Zr and Hf;

(c) dialkoxy transition metal dihalide is diethoxy titanium dichlorideand the likes for V, Zr and Hf;

(d) trialkoxy transition metal monohalide is triethoxy titanium chlorideand the likes for V, Zr and Hf; and

(e) tetraalkoxy transition metal is selected from a group comprising oftetrabutoxy titanium and tetraethoxy titanium and the likes for V, Zrand Hf.

The present invention also provides a process for preparation of aZiegler-Natta catalyst system, said process comprising contacting thecatalyst composition as obtained above with at least one cocatalyst, andat least one external electron donor to obtain a Ziegler-Natta catalystsystem.

The present invention also provides a method of polymerizing and/orcopolymerizing olefins, said method comprising the step of contacting anolefin having C2 to C20 carbon atoms under a polymerizing condition withthe Ziegler-Natta catalyst system as obtained above.

The present invention provides the catalyst composition which includescombination of magnesium moiety, titanium moiety and an internal donor.The magnesium moiety includes the stable solid organomagnesium compoundof the present invention. In an embodiment, the invention provides themethod of synthesis of olefin polymerizing catalyst, comprising ofreacting the organomagnesium compound with liquid titanium compoundwhich includes tetravalent titanium compound represented asTi(OR)_(p)X_(4-p) where X can be halogen selected from Cl or Br or I, Ris a hydrocarbon group and p is an integer varying from 0-4. Specificexamples of the titanium compound include, not limited to titaniumtetrahalides such as titanium tetrachloride, titanium tetrabromide,titanium tetraiodide; alkoxytitanium trihalide/aryloxytitanium trihalidesuch as methoxytitanium trichloride, ethoxytitanium trichloride,butoxytitanium trichloride, phenoxytitanium trichloride;dialkoxytitanium dihalides such as diethoxy titanium dichloride;trialkoxytitanium monohalide such as triethoxy titanium chloride; andtetraalkoxytitanium such as tetrabutoxy titanium, tetraethoxy titanium,and mixtures thereof, with titanium tetrachloride being preferred. Thetitanium compounds may be used alone or in the form of mixture thereof.

According to the present invention, the magnesium moiety includes thestable solid organomagnesium compound. In an embodiment, the contact oforganomagnesium compound with titanium compound can be either neat or insolvent which can be chlorinated or non chlorinated aromatic oraliphatic in nature examples not limiting to benzene, decane, kerosene,ethyl benzene, chlorobenzene, dichlorobenzene, toluene, o-chlorotoluene,xylene, dichloromethane, chloroform, cyclohexane and the like,comprising from 5 to 95 volume percent. In another embodiment, thestable solid organomagnesium compound can be used as solid or in solventwhich can be chlorinated or non chlorinated aromatic or aliphatic innature examples not limiting to benzene, decane, kerosene, ethylbenzene, chlorobenzene, dichlorobenzene, toluene, o-chlorotoluene,xylene, dichloromethane, chloroform, cyclohexane and the like,comprising from 5 to 95 volume percent.

In an embodiment, either the titanium compound is added to theorganomagnesium compound or vice-verse, preferably, organomagnesiumcompound is added to titanium compound.

In another embodiment, this addition is either one shot or dropwise orcontrolled. In another embodiment, the contact temperature oforganomagnesium and titanium compound is preferably between about −50°C. and about 150° C., and more preferably between about −30° C. andabout 120° C.

The liquid titanium compound helps in the formation of amorphous MgCl₂as it acts as halogenating agent as well as is dispersed and supportedon the catalyst surface. Moreover, the removal of alkoxy group from thesolution, results in the precipitation of the solid component, havingespecially desired surface properties and particle shape. Moreimportant, the particles are uniform in shape. In an embodiment, thetitanium compound is added in amounts ranging from usually about atleast 1 to 200 moles, preferably, 3 to 200 moles and more preferably, 5mole to 100 moles, with respect to one mole of magnesium.

While preparing the catalyst composition, magnesium component iscontacted with the titanium component along with the internal donor toget the solid titanium component. In one embodiment, magnesium andtitanium component can be made to come in contact with the internalelectron donor.

In another embodiment, the solid titanium catalyst component is made bycontacting a magnesium compound and a titanium compound in the presenceof an internal electron donor compound.

In still another embodiment, the solid titanium catalyst component ismade by forming a magnesium based catalyst support optionally with thetitanium compound and optionally with the internal electron donorcompound, and contacting the magnesium based catalyst support with thetitanium compound and the internal electron donor compound.

The present invention provides the catalyst composition which includescombination of magnesium moiety, titanium moiety and an internal donor.The magnesium moiety includes the stable solid organomagnesium compound.In an embodiment, internal electron donor is selected from phthalates,benzoates, diethers, succinates, malonates, carbonates, and combinationsthereof. Specific examples include, but are not limited to di-n-butylphthalate, di-i-butyl phthalate, di-2-ethylhexyl phthalate, di-n-octylphthalate, di-i octyl phthalate, di-n-nonyl phthalate, methyl benzoate,ethyl benzoate, propyl benzoate, phenyl benzoate, cyclohexyl benzoate,methyl toluate, ethyl toluate, p-ethoxy ethyl benzoate, p-isopropoxyethyl benzoate, diethyl succinate, di-propyl succinate, diisopropylsuccinate, dibutyl succinate, diisobutyl succinate, diethyl malonate,diethyl ethylmalonate, diethyl propyl malonate, diethylisopropylmalonate, diethyl butylmalonate, diethyl1,2-cyclohexanedicarboxylate, di-2-ethylhexyl1,2-cyclohexanedicarboxylate, di-2-isononyl1,2-cyclohexanedicarboxylate, methyl anisate, ethyl anisate and diethercompounds such as 9,9-bis(methoxymethyl)fluorene,2-isopropyl-2-isopentyl-1,3-dimethoxypropane,2,2-diisobutyl-1,3-dimethoxypropane,2,2-diisopentyl-1,3-dimethoxypropane,2-isopropyl-2-cyclohexyl-1,3-dimethoxypropane, preferably di-iso-butylphthalate.

The “internal electron donor” is a compound that is added during theformation of catalyst composition where it is acting as Lewis base i.e.donating the electron pairs to the metal present in the catalystcomposition. The internal electron donor stabilizes the primarycrystallites of magnesium dihalide which is generated in-situ. Apartfrom this, the internal donor also being better Lewis base havepreferred coordination with the higher acidity coordination sites onmagnesium dihalide matrix which in turn avoid the coordination oftitanium and hence prevents the formation of inactive sites. They alsoincrease the activity of low active sites. This in all enhances thecatalyst stereoselectivity. All internal electron donor compoundscommonly used in the art can be used in the present invention. Inanother embodiment, the internal electron donor is used in an amount offrom 0 to 1 moles, preferably from 0.01 to 0.5 moles, with respect toone mole of magnesium.

The present invention provides the catalyst composition which includescombination of magnesium moiety, titanium moiety and an internal donor.The magnesium moiety includes the solid organomagnesium compound. In anembodiment, the addition of internal is either to the organomagnesiumcompound or to the titanium component, preferably to organomagnesiumcompound. The contact temperature of internal donor depends upon towhich component it is being added. In an embodiment, the contact time ofthe desired component with the internal electron donor is eitherimmediate or at least 1 minutes to 60 minutes at contact temperature ofpreferably between about −50° C. and about 100° C., and more preferablybetween about −30° C. and about 90° C. in another embodiment, theinternal donor may be added in single step or in multiple steps.

The contact procedure for titanium and magnesium component is slowlywith dropwise addition at desired temperature and then heated toactivate the reaction between both the components.

In a preferred embodiment, this reaction system is gradually heated tothe temperature effective to carry out the reaction, preferably about−50° C. and about 150° C., and more preferably about −30° C. and about120° C., and heating is instigated at a rate of 0.1 to 10.0° C./minute,or at a rate of 1 to 5.0° C./minute. The resultant is the solidcomponent in the solvent comprising of magnesium, titanium and halogencomponents.

The procedure of contacting the titanium component may be repeated one,two, three or more times as desired. In an embodiment, the resultingsolid material recovered from the mixture can be contacted one or moretimes with the mixture of liquid titanium component in solvent for atleast 10 minutes up to 60 minutes, at temperature from about 25° C. toabout 150° C., preferably from about 30° C. to about 110° C.

The resulting solid component comprising of magnesium, titanium,halogen, alcohol and the internal electron donor can be separated fromthe reaction mixture either by filtration or decantation and finallywashed with inert solvent to remove unreacted titanium component andother side products. Usually, the resultant solid material is washed oneor more times with inert solvent which is typically a hydrocarbonincluding, not limiting to aliphatic hydrocarbon like isopentane,isooctane, hexane, pentane or isohexane. In an embodiment, the resultingsolid mixture is washed one or more times with inert hydrocarbon basedsolvent preferably, hexane at temperature from about 20° C. to about 80°C., preferably from about 25° C. to about 70° C. The solid catalyst canbe separated and dried or slurried in a hydrocarbon specifically heavyhydrocarbon such as mineral oil for further storage or use.

In an embodiment, the catalyst composition includes from about 2.0 wt %to 20 wt % of internal electron donor, titanium is from about 0.5 wt %to 10.0 wt % and magnesium is from about 10 wt % to 20 wt %.

The present invention provides the catalyst system for polymerization ofolefins. In the embodiment, the method of polymerization process isprovided where the catalyst system is contacted with olefin underpolymerization conditions. The catalyst system includes catalystcomposition, organoaluminum compounds and external electron donors. Thecatalyst composition includes combination of magnesium moiety, titaniummoiety and an internal donor. The magnesium moiety includes the stablesolid organomagnesium compound.

Further, the present invention provides a method of polymerizing and/orcopolymerizing olefins where the catalyst system is contacted witholefin under polymerization conditions. The catalyst system includescatalyst composition, cocatalyst and external electron donors. Thecatalyst composition includes combination of magnesium moiety, titaniummoiety and an internal donor. The magnesium moiety includes the stablesolid organomagnesium compound. The co-catalyst may include hydrides,organoaluminum, lithium, zinc, tin, cadmium, beryllium, magnesium, andcombinations thereof. In an embodiment, the preferred co-catalyst isorganoaluminum compounds.

In another embodiment the catalyst system includes catalyst composition,organoaluminum compounds and external electron donors. The catalystcomposition includes combination of magnesium moiety, titanium moietyand an internal donor. The magnesium moiety includes the stable solidorganomagnesium compound.

The olefins according to the present invention includes from C2-C20. Theratio of titanium (from catalyst composition): aluminum (fromorganoaluminum compound): external donor can be from 1:5-1000:0-250,preferably in the range from 1:25-500:25-100.

The present invention provides the catalyst system. The catalyst systemincludes catalyst component, organoaluminum compounds and externalelectron donors. In an embodiment, the organoaluminum compounds include,not limiting, alkylaluminums such as trialkylaluminum such as preferablytriethylaluminum, triisopropylaluminum, triisobutylaluminum,tri-n-butylaluminum, tri-n-hexylaluminum, tri-n-octylaluminum;trialkenylaluminums such as triisoprenyl aluminum; dialkylaluminumhalides such as diethylaluminum chloride, dibutylaluminum chloride,diisobutylaluminum chloride and diethylaluminum bromide; alkylaluminumsesquihalides such as ethylaluminum sesquichloride, butylaluminumsesquichloride and ethylaluminum sesquibromide; dialkylaluminum hydridessuch as diethylaluminum hydride and dibutylaluminum hydride; partiallyhydrogenated alkylaluminum such as ethylaluminum dihydride andpropylaluminum dihydride and aluminoxane such as methylaluminoxane,isobutylaluminoxane, tetraethylaluminoxane and tetraisobutylaluminoxane;diethylaluminum ethoxide.

The mole ratio of aluminum to titanium is from about 5:1 to about 1000:1or from about 10:1 to about 700:1, or from about 25:1 to about 500:1.

The present invention provides the catalyst system. The catalyst systemincludes catalyst component, organoaluminum compounds and externalelectron donors. The external electron donors are organosiliconcompounds, diethers and alkoxy benzoates. The external electron donorfor olefin polymerization when added to the catalytic system as a partof co-catalyst retains the stereospecificity of the active sites,convert non-stereospecific sites to stereospecific sites, poisons thenon-stereospecific sites and also controls the molecular weightdistributions while retaining high performance with respect to catalyticactivity. The external electron donors which are generally organosiliconcompounds includes but are not limited to trimethylmethoxy silane,trimethylethoxy silane, dimethyldimethoxysilane, dimethyldiethoxysilane,diisopropyldimethoxysilane, diisobutyldimethoxysilane,t-butylmethyldimethoxysilane, t-butylmethyldiethoxysilane,t-amylmethyldiethoxysilane, dicyclopentyldimethoxysilane,diphenyldimethoxysilane, phenylmethyldimethoxysilane,diphenyldiethoxysilane, bis-o-tolydimethoxysilane,bis-m-tolydimethoxysilane, bis-p-tolydimethoxysilane,bis-p-tolydiethoxysilane, bisethylphenyldimethoxysilane,dicyclohexyldimethoxysilane, cyclohexylmethyldimethoxysilane,cyclohexylmethyldiethoxysilane, ethyltrimethoxysilane,ethyltriethoxysilane, vinyltrimethoxysilane, methyltrimethoxysilane,n-propyltriethoxysilane, decyltrimethoxysilane, decyltriethoxysilane,phenyltrimethoxysilane, gamma-chloropropyltrimethoxysilane,methyltriethoxysilane, ethyltriethoxysilane, vinyltriethoxysilane,t-butyltriethoxysilane, n-butyltriethoxysilane, iso-butyltriethoxysilane, phenyltriethoxysilane,gamma-aminopropyltriethoxysilane, cholotriethoxysilane,ethyltriisopropoxysilane, vinyltirbutoxysilane,cyclohexyltrimethoxysilane, cyclohexyltriethoxysilane,2-norbornanetrimethoxysilane, 2-norbornanetriethoxysilane,2-norbornanemethyldimethoxysilane, ethyl silicate, butyl silicate,trimethylphenoxysilane, and methyltriallyloxysilane,cyclopropyltrimethoxysilane, cyclobutyltrimethoxysilane,cyclopentyltrimethoxysilane, 2-methylcyclopentyltrimethoxysilane,2,3-dimethylcyclopentyltrimethoxysilane,2,5-dimethylcyclopentyltrimethoxysilane, cyclopentyltriethoxysilane,cyclopentenyltrimethoxysilane, 3-cyclopentenyltrimethoxysilane,2,4-cyclopentadienyltrimethoxysilane, indenyltrimethoxysilane andfluorenyltrimethoxysilane; dialkoxysilanes such asdicyclopentyldimethoxysilane, bis(2-methylcyclopentyl)dimethoxysilane,bis(3-tertiarybutylcyclopentyl)dimethoxysilane,bis(2,3-dimethylcyclopentyl)dimethoxysilane,bis(2,5-dimethylcyclopentyl)dimethoxysilane,dicyclopentyldiethoxysilane, dicyclobutyldiethoxysilane,cyclopropylcyclobutyldiethoxysilane, dicyclopentenyldimethoxysilane,di(3-cyclopentenyl)dimethoxysilane,bis(2,5-dimethyl-3-cyclopentenyl)dimethoxysilane,di-2,4-cyclopentadienyl)dimethoxysilane,bis(2,5-dimethyl-2,4-cyclopentadienyl)dimethoxysilane,bis(1-methyl-1-cyclopentylethyl)dimethoxysilane,cyclopentylcyclopentenyldimethoxysilane,cyclopentylcyclopentadienyldimethoxysilane, diindenyldimethoxysilane,bis(1,3-dimethyl-2-indenyl)dimethoxysilane,cyclopentadienylindenyldimethoxysilane, difluorenyldimethoxysilane,cyclopentylfluorenyldimethoxysilane and indenylfiuorenyldimethoxysilane;monoalkoxysilanes such as tricyclopentylmethoxysilane,tricyclopentenylmethoxysilane, tricyclopentadienylmethoxysilane,tricyclopentylethoxysilane, cyclopentylmethylmethoxysilane,dicyclopentylethylmethoxysilane, dicyclopentylmethylethoxysilane,cyclopentyldimethylmethoxysilane, cyclopentyldiethylmethoxysilane,cyclopentyldimethylethoxysilane,bis(2,5-dimethylcyclopentyl)cyclopentylmethoxysilane,dicyclopentylcyclopentenylmethoxysilane,dicyclopentylcyclopentenadienylmethoxysilane,diindenylcyclopentylmethoxysilane andethylenebis-cyclopentyldimethoxysilane; aminosilanes such asaminopropyltriethoxysilane, n-(3-triethoxysilylpropyl)amine,bis[(3-triethoxysilyl)propyl]amine, aminopropyltrimethoxysilane,aminopropylmethyldiethoxysilane, hexanediaminopropyltrimethoxysilane.

In an embodiment, the external electron donor, other than organosiliconcompounds include, but not limited to amine, diether, esters,carboxylate, ketone, amide, phosphine, carbamate, phosphate, sulfonate,sulfone and/or sulphoxide.

The external electron donor is used in such an amount to give a molarratio of organoaluminum compound to the said external donor from about0.1 to 500, preferably from 1 to 300.

In the present invention, the polymerization of olefins is carried outin the presence of the catalyst system described above. The catalystsystem is contacted with olefin under polymerization conditions toproduce desired polymer products. The polymerization process can becarried out such as by slurry polymerization using an inert hydrocarbonsolvent as a diluent, or bulk polymerization using the liquid monomer asa reaction medium and in gas-phase operating in one or more fluidized ormechanically agitated bed reactors. In an embodiment, polymerization iscarried out as such. In another embodiment, the copolymerization iscarried out using at least two polymerization zones.

The catalyst of the invention can be used in the polymerization of theabove-defined olefin CH₂═CHR, the examples of said olefin includeethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-hexene, and1-octene.

In particular, said catalyst can be used to produce, the followingproducts such as high-density polyethylene (HDPE, having a densityhigher than 0.940 g/cm³), which includes ethylene homopolymer andcopolymer of ethylene and α-olefins having 3 to 12 carbon atoms; linearlow-density polyethylene (LLDPE, having a density lower than 0.940g/cm³), and very low density and ultra low density polyethylene (VLDPEand ULDPE, having a density lower than 0.920 g/cm3, and as low as 0.880g/cm3), consisting of the copolymer of ethylene and one or morea-olefins having 3 to 12 carbon atoms, wherein the molar content of theunit derived from ethylene is higher than 80%; elastomeric copolymer ofethylene and propylene, and elastomeric terpolymers of ethylene,propylene and butene-1 as well as diolefins at a small ratio, whereinthe weight content of the unit derived from ethylene is between about30% and 70%; isotactic polypropylene and crystalline copolymer ofpropylene and ethylene and/or other a-olefins, wherein the content ofthe unit derived from propylene is higher than 85% by weight (randomcopolymer); impact propylene polymer, which are produced by sequentialpolymerization of propylene and the mixture of propylene and ethylene,with the content of ethylene being up to 40% by weight; copolymer ofpropylene and 1-butene, containing a great amount, such as from 10 to 40percent by weight, of unit derived from 1-butene. It is especiallysignificant that the propylene polymers produced by using the catalystsof the invention have high isotactic index.

The polymerization is carried out at a temperature from 20 to 120° C.,preferably from 40 to 80° C. When the polymerization is carried out ingas phase, operation pressure is usually in the range of from 5 to 100bar preferably from 10 to 50 bar. The operation pressure in bulkpolymerization is usually in the range of from 10 to 150 bar, preferablyfrom 15 to 50 bar. The operation pressure in slurry polymerization isusually in the range of from 1 to 10 bar, preferably from 2 to 7 bar.Hydrogen can be used to control the molecular weight of polymers.

In the present invention, the polymerization of olefins is carried outin the presence of the catalyst system described in the invention. Thedescribed catalyst can be directly added to the reactor forpolymerization or can be prepolymerized i.e. catalyst is subjected to apolymerization at lower conversion extent before being added topolymerization reactor.

Prepolymerization can be performed with olefins preferably ethyleneand/or propylene where the conversion is controlled in the range from0.2 to 500 gram polymer per gram catalyst. In the present invention, thepolymerization of olefins in presence of the described catalyst systemleads to the formation of polyolefins having xylene solubility (XS)ranging from about 0.2% to about 15%. In another embodiment, polyolefinshave xylene solubility (XS) from about 2% to about 8%. Here XS refers tothe weight percent of polymer that get dissolves into hot xylenegenerally for measuring the tacticity index such as highly isotacticpolymer will have low XS % value i.e. higher crystallinity, whereas lowisotactic polymer will have high XS % value.

In an embodiment of the invention, the catalyst efficiency (measured askilogram of polymer produced per gram of catalyst) of the describedcatalyst system is at least about 30. In another embodiment, thecatalyst efficiency of the described catalyst system is at least about60.

The present invention provides the catalyst system. The catalysts systemwhen polymerizes olefins provides polyolefins having melt flow indexes(MFI) of about 0.1 to about 100 which is measured according to ASTMstandard D1238. In an embodiment, polyolefins having MFI from about 0.5to about 30 are produced.

The present invention provides the catalyst system. The catalysts systemwhen polymerizes olefins provides polyolefins having bulk densities (BD)of at least about 0.3 cc/g.

The following non-limiting examples illustrate in details about theinvention. However, they are, not intended to be limiting the scope ofpresent invention in any way.

EXAMPLE 1 Preparation of Organomagnesium Compound

In 500 ml glass reactor maintained at 0° C., calculated amount ofmagnesium (powder or turnings) were weighed and added into the reactorfollowed by diethyl ether followed by addition of calculated amount oforganohalide. This mixture was stirred and after the activation of thereaction, the mixture was allowed to be maintained at same temperatureuntil all magnesium has reacted. To the resulting solution, thecalculated amount of alcohol was added dropwise over a period of 1-2 h.After the completion of addition, the solution was allowed to stir foranother 0.5 h. Finally, the ether was evaporated and solid compound wasanalyzed.

The organomagnesium compounds synthesized by the above procedure havebeen tabulated in Table 1.

TABLE 1 Benzyl Mg chloride BuCl Alcohol Mg Cl Precursor Ratio RatioRatio Ratio Solvent Alcohol (wt %) (wt %) Remark MGP#25   1.3 1 0 0 DEE— 12.6 18.7 MGP#27  1^(a) 0 0 1 DEE EHA 12.6 18.7 ^(a)MGP#25 as startingmaterial MGP#37 1 1.1 0 1 DEE EHA 12.7 18.8 MGP#42 1 1.1 0 1 DEE Benzyl14.5 21.2 Alcohol MGP#43 1 0 1.1 1 DEE EHA 12.6 18.7 MGP#45 1 1.1 0 1DEE isobutanol 18.2 26.7 MGP#53 1 1.1 0 1 DEE Catechol 21.2 30.9 MGP#571 1.1 0 1 DEE Cresol 14.5 21.1 MGP#61 1 1.1 0 1 DEE EHA 12.5 18.9 MGP#631 1.1 0 1 DEE/toluene EHA (20:80) MGP#64 1 1.1 0 1 DEE isobutanol 17.125.2 Isobutanol/ hexane used as precipitating agent MGP#66 1 1.1 0 1 DEEEHA 12.7 18.9 MGP#67 1 0 1.1 1 DEE EHA 12.5 18.9 MGP#68 1 1.1 0 1 DEEEHA 12.5 18.7 MGP#73 1 1.1 0 1 DEE 3-methoxy- 12.4 18.7 1-butanol MGP#741 1.1 0 1 DEE 3-methoxy- 12.5 18.5 1-butanol MGP#75 1 1.1 0 1 DEE EHA12.5 18.7 MGP#76 1 1.1 0 1 DEE EHA 12.7 18.9 MGP#83 1 0 1.1 1 DEE/ EHA12.5 18.5 chlorobenzene MGP#84 1 1.1 0 1 DEE/ EHA 12.5 18.7chlorobenzene MGP#85 1 1.1 0 1 DEE/ EHA 12.6 18.7 chlorobenzene MGP#87 11.1 0 1 DEE EHA 12.7 18.5 MGP#88 1 1.1 0 1 DEE EHA 12.6 18.9 MGP#90 11.1 0 1 DEE EHA 12.5 18.6 MGP#91 1 1.1 0 1 DEE EHA 12.6 18.5 MGP#92 1 01.1 1 DEE EHA 12.6 18.6 Reaction @30° C. MGP#93 1 1.1 0 1 DEE EHA 12.518.5 EHA addition @ 0° C. MGP#94 1 1.1 0 1 DEE EHA 12.7 18.5 MGP#95 11.1 0 1 DEE EHA 12.6 18.9 Reaction @30° C. MGP#96 1 1.1 0 1 DEE EHA 12.418.6 MGP#97 1 1.1 0 1 DEE EHA 12.6 18.9 MGP#137 1 1.1 0 1 DEE EHA 12.518.7 Benzyl chloride/EHA mixture added EHA = 2-ethyl-1-hexanol; DEE =diethyl ether

Table 1 represents the conditions for preparation of the solidorganomagnesium compound using different alcohols and organohalidesunder different reaction conditions.

EXAMPLE 2 Preparation of the Catalyst Component

To 60 ml of TiCl₄ solution maintained at desired temperature, added 100ml of the organomagnesium precursor along with internal donor(ID/Mg=0.11 moles) over a period of 10 min and stirred. After the systemhas attained the desired temperature, the resultant solution wasmaintained at the same temperature for 15 min. The resultant solutionwas clear orange in color. Gradually the reaction temperature wasincreased to 110° C. and maintained for 1 h. After settling anddecantation, the suspended solid was again treated with 60 ml TiCl₄ and60 ml chlorobenzene and after temperature reached 110° C., the mixturewas maintained under stirring for 15 minutes. The above step was againrepeated. After the reaction was finished, the solid was decanted andwashed sufficiently with hexane at 70° C., respectively and furtherdried under hot nitrogen till freely flowing.

The solid catalysts composition synthesized by the above procedure hasbeen tabulated in Table 2.

TABLE 2 Precursor & TiCl₄ Internal contact donor temperature addition TiMg Donor Catalyst Precursor ° C. ° C. Remark (wt %) (wt %) (wt %) ZN#102MGP#27 40 90 4.5 15.2 19.3 ZN#119 MGP#45 −5 −5 2.6 15.8 24.3 ZN#120MGP#37 −5 −5 3.3 18.7 10.5 ZN#121 MGP#37 −5 −5 Three titanation 2.9 17.417.0 @110° C. ZN#129 MGP#37 −5 −5 two titanation @ 3.1 16.4 20.1 120° C.ZN#131 MGP#37 −5 −5 Three titanation 2.8 17.5 17.0 @120° C. - 1^(st): 60ml TiCl₄; 2^(nd): 40 ml TiCl₄; 3^(rd): 20 ml TiCl₄ ZN#132 MGP#37 −5 −5Three titanation 3.8 16.5 17.0 @120° C. Two stage DIBP addition at1^(st) titanation - 1^(st) @ −5° C.; 2^(nd) @ 70° C. ZN#133 MGP#37 −5 −5Three titanation 2.7 16.7 20.5 @120° C. ZN#134 MGP#37 −5 −5 Threetitanation 5.2 18.7 3.1 @110° C. Two stage DIBP addition at 1^(st)titanation - 1^(st) @ −5° C.; 2^(nd) @ 70° C. ZN#135 MGP#37 −5 −5 Threetitanation 2.5 18.0 13.6 @110° C. ZN#145 MGP#37 −5 −5 Three titanation3.0 18.2 12.5 @110° C.; TiCl₄(40 ml) ZN#146 MGP#37 −5 −5 Threetitanation 4.9 11.9 17.5 @110° C.; Diether as internal donor ZN#149MGP#64 −5 −5 Three titanation 2.2 11.5 11.1 @110° C. ZN#150 MGP#61 −5 −5Three titanation 2.3 17.5 15.4 @110° C. ZN#152 MGP#37 −5 −5 Threetitanation 3.3 17.5 15.2 @110° C. ZN#153 MGP#37 −5 −5 Three titanation2.5 18.6 14.4 @110° C.; Temp ramping from −5° C. to 110° C. in 50 minZN#154 MGP#66 −5 −5 Three titanation 3.9 14.6 14.2 @110° C. ZN#156MGP#67 −5 −5 Three titanation 2.5 15.9 14.4 @120° C. ZN#157 MGP#66 −5 −5Three titanation 3.1 18.1 8.7 @110° C.; (DIBP/Mg = 0.05 moles) ZN#158MGP#67 −5 −5 Three titanation 1.8 15.7 17.7 @110° C.; (DIBP/Mg = 0.05moles) ZN#159 MGP#66 −5 −5 Three titanation 2.8 17.5 12.2 @100° C.;(DIBP/Mg = 0.05 moles) ZN#160 MGP#66 −5 −5 Three titanation 3.1 17.112.2 @100° C.; (DIBP/Mg = 0.05 moles) ZN#161 MGP#66 −5 −5 Threetitanation 1.1 16.8 14.5 @110° C.; (DIBP/Mg = 0.05 moles) ZN#162 MGP#66−5 −5 Three titanation 2.1 16.9 13.5 @110° C. ZN#164 MGP#66 −5 −5 Threetitanation 2.8 17.5 12.2 @110° C.; Additional chlorobenzene washingbefore hexane washing ZN#165 MGP#66 −5 −5 Three titanation 2.9 16.9 14.1@110° C.; ZN#168 MGP#66 −5 −5 Three titanation 2.1 13.5 14.1 @110° C.;(Ti/Mg = 6.7) ZN#169 MGP#66 −5 −5 Three titanation 3.6 15.3 @110° C.;MGP dissolved in decane ZN#170 MGP#66 −5 −5 Three titanation 2.7 17.2@110° C.; MGP dissolved in mineral oil ZN#171 MGP#66 −5 −5 Threetitanation 2.9 18.5 12.7 @110° C.; (DIBP/Mg = 0.05 moles) ZN#172 MGP#66−5 −5 Three titanation 2.7 14.8 13.3 @100° C. ZN#173 MGP#66 −5 −5 Threetitanation 1.3 18.0 11.9 filtered @110° C. ZN#175 MGP#66 −5 −5 Threetitanation 2.6 17.2 10.4 @110° C.; Charging of TiCl₄ to MGP/ID solutionZN#176 MGP#66 −5 −5 Three titanation 2.6 16.9 10.8 @110° C.; Charging ofTiCl₄ to MGP/ID solution ZN#179 MGP#67 −5 −5 Three titanation 2.7 18.415.2 @110° C.; RPM 500 ZN#180 MGP#67 −5 −5 Three titanation 2.6 17.6@110° C.; RPM 250 ZN#188 MGP#75 −5 −5 Three titanation 2.7 18.3 12.5@110° C. ZN#189 MGP#75 −20 −20 Three titanation 2.4 16.7 14.4 @110° C.ZN#191 MGP#75 −20 −20 Three titanation 3.4 17.1 @110° C.; Temp rampingfrom −20° C. to 110° C. in 60 min ZN#192 MGP#75 −20 −20 Three titanation3.1 17.1 14.6 @110° C.; Temp ramping from −20° C. to 110° C. in 120 minZN#193 MGP#75 −20 −20 Three titanation 3.0 17.4 13.6 @110° C.; Tempramping from −20° C. to 110° C. in 30 min ZN#194 MGP#75 −20 −20 Threetitanation 3.1 17.1 15.5 @110° C.; Temp ramping from −20° C. to 110° C.in 120 min; RPM 250 ZN#194 MGP#75 −20 −20 Three titanation 2.5 17.3 14.2@110° C.; Temp ramping from −20° C. to 110° C. in 120 min; RPM 175ZN#195 MGP#75 −20 −20 Three titanation 2.2 16.0 16.1 @110° C.; Tempramping from −20° C. to 110° C. in 120 min; RPM 750 ZN#196 MGP#76 −20−20 Three titanation 2.3 17.5 14.5 @110° C.; Temp ramping from −20° C.to 110° C. in 120 min ZN#207 MGP#84 −20 −20 Three titanation 1.3 15.511.2 @110° C.; Temp ramping from −20° C. to 110° C. in 120 min ZN#207MGP#83 −20 −20 Three titanation 1.3 19.1 11.0 @110° C.; Temp rampingfrom −20° C. to 110° C. in 120 min ZN#209 MGP#85 −20 −20 Threetitanation 1.8 18.5 9.3 @110° C.; Temp ramping from −20° C. to 110° C.in 120 min ZN#218 MGP#75 −20 −20 Three titanation 2.5 18.6 12.6 @110°C.; Temp ramping from −20° C. to 110° C. in 120 min ZN#288 MGP#137 −5 −5Three titanation 2.4 19.4 11.8 @110° C.; Temp ramping from −5° C. to110° C.

Table 2 represents the preparation of solid catalyst usingorganomagnesium compound as precursor under different reactionconditions.

EXAMPLE 3 Slurry Polymerization of Propylene

Propylene polymerization was carried out in 1 L Buchi reactor which waspreviously conditioned under nitrogen. The reactor was charged with 250ml of dry hexane containing solution of 10 wt % triethylaluminumfollowed by 100 ml of dry hexane containing 10 wt % solution oftriethylaluminum, 5 wt % solution of cyclohexy methyl dimethoxysilaneand weighed amount of catalyst. The reactor was pressurized withhydrogen to 60 ml then charged with 71 psi of propylene under stirringat 750 rpm. The reactor was heated to and then held at 70° C. for 2hour. At the end, the reactor was vented and the polymer was recoveredat ambient conditions.

Catalyst performance and polymer properties has been tabulated in Table3

TABLE 3 CATALYST POLYMERIZATION POLYMER ANALYSIS Cat Activity MFI wtAl/Ti H2 Al/Do kgPP/ @2.16 XS BD Cat No (mg) ratio ml ratio gcat kg wt %g/cc ZN#102 15.5 250 10 20 5.8 — 4.2 ZN#121 14.2 500 10 20 11 — 2.0 0.4110.5 500 10 20 13.3 5.3 3.2 0.40 10.5 500 10 30 14.3 4.8 3.7 0.41 10.3500 10 10 13.2 4.1 2.1 0.40 10.2 500 10 5 12.4 3.6 5.5 0.42 10.2 500 1040 10.4 — 6.6 0.41 10.6 500 0 30 7.7 — 4.2 0.40 ZN#129 10.6 500 10 2010.6 2.6 3.0 0.27 ZN#131 10.6 500 10 20 6.9 2.5 2.0 0.36 ZN#132 10.3 50010 20 15.1 3.9 3.2 0.35 ZN#133 10.2 500 10 20 13.5 2.4 2.1 0.43 ZN#13510.4 500 10 20 10.8 0.5 1.9 0.38 ZN#145 10.5 500 10 20 9.9 2.1 2.6 0.37ZN#149 10.8 500 10 20 9.5 2.2 1.6 0.38 ZN#154 10.3 500 10 20 12.8 6.01.9 0.34 ZN#156 10.2 500 10 20 12.7 1.6 2.5 0.36 ZN#157 10.0 500 10 2014.7 5.4 2.5 0.38 ZN#158 10.3 500 10 20 7.1 3.6 2.1 0.37 ZN#159 10.5 50010 20 8.6 3.4 2.2 0.39 ZN#160 10.0 500 10 20 11.7 3.0 2.0 0.40 ZN#16115.0 500 10 20 9.8 2.4 2.0 0.32 ZN#162 10.3 500 10 20 9.0 2.7 2.0 0.34ZN#164 10.3 500 10 20 7.8 3.7 1.6 0.35 ZN#165 10.6 500 10 20 12.5 8.81.2 0.41 ZN#168 10.3 500 10 20 9.0 2.6 1.1 0.33 ZN#169 10.7 500 10 208.3 3.2 1.5 0.33 ZN#170 10.8 500 10 20 6.3 5.6 1.1 0.32 ZN#171 10.3 50010 20 10.8 2.2 1.3 0.38 ZN#172 10.2 500 20 20 9.0 4.0 1.9 0.32 ZN#17310.9 500 10 20 1.8 1.6 2.5 0.31 ZN#175 10.1 500 10 20 13.0 2   1.8 0.43ZN#176 10.6 500 10 20 13.7 3.4 1.3 0.42 ZN#179 10.7 500 10 20 10.2 2.81.9 0.27 ZN#180 10.0 500 10 20 11.2 2.4 2.3 0.29 ZN#189 10.4 500 10 208.3 2.7 2.0 0.32 ZN#188 10.3 500 10 20 11.3 3.0 1.7 0.36 ZN#191 10.6 50010 20 10.6 2.3 1.7 0.32 ZN#192 10.2 500 10 20 11.9 3.2 2.2 0.37 ZN#19310.2 500 10 20 9.5 4.7 1.7 0.33 ZN#194 10.4 500 10 20 9.3 8.6 1.9 0.31ZN#195 10.7 500 10 20 10.1 3.3 1.4 0.35 ZN#196 10.0 500 10 20 10.5 4.22.3 0.32 ZN#207 10.8 500 10 20 7.6 7.2 2.9 0.37 ZN#208 10.8 500 10 200.8 4.5 3.1 0.35 ZN#209 10.8 500 10 20 9.7 3.1 2.3 0.37 ZN#288 10.0 50010 30 5.5 5.3 3.6 0.45

Table 3 represents the propylene polymerization using different catalystsynthesized using different organomagnesium compounds as precursors. Thecatalysts synthesized under different conditions were found to be activefor propylene polymerization.

We claim:
 1. A catalyst composition as obtained by the process asclaimed in claim 1, said catalyst composition comprising a combinationof 2.0 wt % to 20 wt % of an internal electron donor, 0.5 wt % to 10.0wt % of a titanium and 10 wt % to 20 wt % of a magnesium.
 2. A processfor preparation of a catalyst system, said process comprising contactingthe catalyst composition with at least one cocatalyst, and at least oneexternal electron donor to obtain the catalyst system.
 3. A catalystsystem comprising a combination of catalyst composition as claimed inclaim 1, organoaluminium compounds cocatalyst and external electrondonors, wherein: the catalyst composition is the combination ofmagnesium moiety, titanium moiety and an internal donor and themagnesium moiety is an organomagnesium precursor; the cocatalyst isselected from a group comprising of hydrides, organoaluminum, lithium,zinc, tin, cadmium, beryllium, magnesium, and combinations thereof; andthe external electron donors is selected from a group comprising oforganosilicon compounds, diethers, alkoxy benzoates, amine, esters,carboxylate, ketone, amide, phosphine, carbamate, phosphate, sulfonate,sulfone, sulphoxide and combinations thereof.
 4. The catalyst system asclaimed in claim 3, wherein: the organomagnesium precursor has theformula {Mg(OR′)X}.a{MgX2}.b{Mg(OR′)2}.c{R′OH}, wherein R′ is selectedfrom a hydrocarbon group, X is selected from a halide group, and a:b:cis in range of 0.01-0.5:0.01-0.5:0.01:5; the organomagnesium precursorhas been formed in a process that includes contacting a magnesium sourcewith a solvating agent, an organohalide and an alcohol to obtain thesolid organomagnesium precursor, wherein: the solvating agent isselected from a group comprising of dimethyl ether, diethyl ether,dipropyl ether, diisopropyl ether, ethylmethyl ether, n-butylmethylether, n-butylethyl ether, di-n-butyl ether, di-isobutyl ether,isobutylmethyl ether, and isobutylethyl ether, dioxane, tetrahydrofuran,2-methyl tetrahydrofuran, tetrahydropyran and combination thereof. 5.The catalyst system as claimed in claim 3, wherein: the cocatalyst isorganoaluminium compound and is selected from a group comprising ofalkylaluminums, trialkenylaluminums, dialkylaluminum halides,alkylaluminum sesquihalides, dialkylaluminum hydrides, partiallyhydrogenated alkylaluminum, aluminoxane, diethylaluminum ethoxide andcombination thereof; the alkylaluminums is selected from a groupcomprising of triethylaluminum, triisopropylaluminum,triisobutylaluminum, tri-n-butylaluminum, tri-n-hexylaluminum,tri-n-octylaluminum; the trialkenylaluminums is selected from a groupcomprising of triisoprenyl aluminum; the dialkylaluminum halides isselected from a group comprising of diethylaluminum chloride,dibutylaluminum chloride, diisobutylaluminum chloride, diethyl aluminumbromide; the alkylaluminum sesquihalides is selected from a groupcomprising of ethylaluminum sesquichloride, butylaluminumsesquichloride, ethylaluminum sesquibromide; the dialkylaluminumhydrides is selected from a group comprising of diethylaluminum hydride,dibutylaluminum hydride; the partially hydrogenated alkylaluminum isselected from a group comprising of ethylaluminum dihydride,propylaluminum dihydride; and the aluminoxane is selected from a groupcomprising of methylaluminoxane, isobutylaluminoxane,tetraethylaluminoxane and tetraisobutylaluminoxane.
 6. The catalystsystem as claimed in claim 3, wherein ratio of catalyst composition(titanium):organoaluminum compound:external donor is in range of1:5-1000:0-250, preferably in the range of 1: 25-500:25-100.
 7. Thecatalyst system as claimed in claim 3, wherein mole ratio of aluminum totitanium is from about 5:1 to about 1000:1 or from about 10:1 to about700:1, or from about 25:1 to about 500:1.
 8. The catalyst system asclaimed in claim 3, wherein the external donors is organosiliconcompounds and is selected from a group comprising oftrimethylmethoxysilane, trimethylethoxysilane, dimethyldimethoxysilane,dimethyldiethoxysilane, diisopropyldimethoxysilane,diisobutyldimethoxysilane, t-butylmethyldimethoxysilane,t-butylmethyldiethoxysilane, t-amylmethyldiethoxysilane,dicyclopentyldimethoxysilane, diphenyldimethoxysilane,phenylmethyldimethoxysilane, diphenyldiethoxysilane,bis-o-tolydimethoxysilane, bis-m-tolydimethoxysilane,bis-p-tolydimethoxysilane, bis-p-tolydiethoxysilane,bisethylphenyldimethoxysilane, dicyclohexyldimethoxysilane,cyclohexylmethyldimethoxysilane, cyclohexylmethyldiethoxysilane,ethyltrimethoxysilane, ethyltriethoxysilane, vinyltrimethoxysilane,methyltrimethoxysilane, n-propyltriethoxysilane, decyltrimethoxysilane,decyltriethoxysilane, phenyltrimethoxysilane,gamma-chloropropyltrimethoxysilane, methyltriethoxysilane,ethyltriethoxysilane, vinyltriethoxysilane, t-butyltriethoxysilane,n-butyltriethoxysilane, iso-butyltriethoxysilane, phenyltriethoxysilane,gamma-aminopropyltriethoxysilane, cholotriethoxysilane,ethyltriisopropoxysilane, vinyltributoxysilane,cyclohexyltrimethoxysilane, cyclohexyltriethoxysilane,2-norbornanetrimethoxysilane, 2-norbornanetriethoxysilane,2-norbornanemethyldimethoxysilane, ethyl silicate, butyl silicate,trimethylphenoxysilane, and methyltriallyloxysilane,cyclopropyltrimethoxysilane, cyclobutyltrimethoxysilane,cyclopentyltrimethoxysilane, 2-methylcyclopentyltrimethoxysilane,2,3-dimethylcyclopentyltrimethoxysilane,2,5-dimethylcyclopentyltrimethoxysilane, cyclopentyltriethoxysilane,cyclopentenyltrimethoxysilane, 3-cyclopentenyltrimethoxysilane,2,4-cyclopentadienyltrimethoxysilane, indenyltrimethoxysilane andfluorenyltrimethoxysilane; dialkoxysilanes such asdicyclopentyldimethoxysilane, bis(2-methylcyclopentyl)dimethoxysilane,bis(3-tertiarybutylcyclopentyl)dimethoxysilane,bis(2,3-dimethylcyclopentyl)dimethoxysilane,bis(2,5-dimethylcyclopentyl)dimethoxysilane,dicyclopentyldiethoxysilane, dicyclobutyldiethoxysilane,cyclopropylcyclobutyldiethoxysilane, dicyclopentenyldimethoxysilane,di(3-cyclopentenyl)dimethoxysilane,bis(2,5-dimethyl-3-cyclopentenyl)dimethoxysilane,di-2,4-cyclopentadienyl)dimethoxysilane,bis(2,5-dimethyl-2,4-cyclopentadienyl)dimethoxysilane,bis(1-methyl-1-cyclopentylethyl)dimethoxysilane,cyclopentylcyclopentenyldimethoxysilane,cyclopentylcyclopentadienyldimethoxysilane, diindenyldimethoxysilane,bis(1,3-dimethyl-2-indenyl)dimethoxysilane,cyclopentadienylindenyldimethoxysilane, difluorenyldimethoxysilane,cyclopentylfluorenyldimethoxysilane and indenylfiuorenyldimethoxysilane;monoalkoxysilanes such as tricyclopentylmethoxysilane,tricyclopentenylmethoxysilane, tricyclopentadienylmethoxysilane,tricyclopentylethoxysilane, cyclopentylmethylmethoxysilane,dicyclopentylethylmethoxysilane, dicyclopentylmethylethoxysilane,cyclopentyldimethylmethoxysilane, cyclopentyldiethylmethoxysilane,cyclopentyldimethylethoxysilane,bis(2,5-dimethylcyclopentyl)cyclopentylmethoxysilane,dicyclopentylcyclopentenylmethoxysilane,dicyclopentylcyclopentenadienylmethoxysilane,diindenylcyclopentylmethoxysilane andethylenebis-cyclopentyldimethoxysilane; aminosilanes such asaminopropyltriethoxysilane, n-(3-triethoxysilylpropyl)amine,bis[(3-triethoxysilyl)propyl]amine, aminopropyltrimethoxysilane,aminopropylmethyldiethoxysilane, hexanediaminopropyltrimethoxysilane andcombination thereof.
 9. The catalyst system as claimed in claim 3,wherein the molar ratio of organoaluminum compound to the external donorfrom about 0.1 to 500, preferably from 1 to
 300. 10. A process ofpolymerizing and/or copolymerizing olefins, said method comprising thestep of contacting an olefin having C2 to C20 carbon atoms under apolymerizing condition with the catalyst system as obtained by claim 3.11. The polymerization process as claimed in claim 10, whereinpolymerization is carried out such as by slurry polymerization using aninert hydrocarbon solvent as a diluent, or bulk polymerization using theliquid monomer as a reaction medium and in gas-phase operating in one ormore fluidized or mechanically agitated bed reactors.
 12. Thepolymerization process as claimed in claim 10, wherein the olefin isselected from a group comprising of ethylene, propylene, 1-butene,4-methyl-1-pentene, 1-hexene, 1-octene and combination thereof.